Fabricating mineral fiber



Sept. 15, 1942. c. L. SAVIDGE FABRICATING MINERAL FIBER 2 Sheets-Sheet 1 Filed June 29, 1940 P 1942- c. L. SAVIDGE 2,295,971

FABRICATING MINERAL FIBER Filed June 29, 1940 2 Sheets-Shet 2 47/77/5/2 A jZzv/i H I%.E -v 254 2 v Patented Sept. 15, 1942 UNITED STATES PATENT OFFICE 2,295,911 FABRICATING MNERAL FIBER Clinton L. Savidge, Toledo, Ohio, asslgnor to Ohio Insulation Company, Toledo, Ohio, a corporation of Ohio Application June 29, 1940, Serial No. 343,249

Claims. (Cl. 154-27) Fig. 1, parts being broken away;

Fig. 3 is a section on the line III-III, Fig. 2, showing the bed longitudinal severing or strip forming means;

Fig. 4 is a section on the line IV-IV, Fig. 2, showing the transverse cutter or severer for the paper backed fiber stock from the longitudinal cutter of Fig. 3 to form such into units or blanks as the bat sections;

Fig. 5 is a view on the line V-V, Fig. 2, on an enlarged scale, showing the severing blast features;

Fig. 6 is a section on the line VI-VI, Fig. 5, showing the details for the stream flow as to the blast;

Fig. 7 is a view on the line VIIV].I, Fig. 6', showing the mechanism for adjusting the stream flow as to the blast;

Fig. 8 is a plan view, with parts broken away, of a production unit or bat; and

Fig. 9 is an enlarged section on the line IXIX, Fig. 8, parts being broken away, of this bat structure.

Supplies In the carrying out of the invention herein, raw material may be discharged from a bin by chute l to floors 2, 3, adjacent the respective cupolas 4, 5. In the instance of mineral wool manufacture, such has been effectively produced from rock or so-called limestone with a silica content. However, advantageous results have followed from so-called blast furnace slag, subdivided say into fragments that will pass through a 3 /2 to 4 inch mesh screen. In the event the silica content of the slag be not up to the proportion desired, silicious rock may be introduced in a suflicient proportion to establish the mix standard found eflicient hereunder for the production of a fibrous material.

In the production of bats hereunder, sheet material may be applied and is sufiicient if such be to but one side of the commin'gled or felted mass of fiber. To such purpose, settling chamber 6 at its discharge end I may carry brackets 8 mounting shaft 3 on which may be placed a plurality of rolls I. These rolls l0 may be of paper sheet ll (Fig. 9) with parallel ribs l2 along one face thereof, such lacy-like ribs being of a bituminous or asphalt character,- Upon the rolls in this rib carrying heat softened face is on the inner side of the roll and, as delivered therefrom, may have such heated from the exposure in the settling chamber ii to soften or render adherent these ribs [2 as anchorage means with the fibrous stock. The body of this paper sheet ll may have water-proof or paraffln outer coating l3. There is thus established a flexible sheet backing for the fibrous stock.

The melt to blast fibering charged through opening 14 in the cupola 5 for melting such down. From the charging floor 2 the attendant may keep proper supply of the fragments delivered into opening I5 for the cupola 4. These respective cupolas have water jacket I 6 (Fig. 6) and take-off openings H for the tap or flow of a stream of molten material therefrom. Fusing or fluxing may be at 2600" F., more or less, according to the character of the mix. The water jacket l6 has portion l8 below the opening I'I, Into this opening l1, against the outer side of the cupola, may be thrust facing l9 as a metal casting having port 20, above which may be placed refractory material or fire brick 2|, thus to protect the facing l9 from the direct action of the heat of the melt in the cupola and leave therebelow a flow-off way 22 for escape of gas above flowing stream 23 on stream bed 24 over the water jacket portion I8. This stream bed portion 24 has forward edge 25 with drop 26 therefrom of a body dimension suflicient for holding the form of the edge 25 notwithstanding the high temperature of the stream 23 as flowing abruptly and continuously thereover. This stream 23 as passing from the edge 25 has dropping portion 21 (Fig. 5) riding on subdivider portion 28 for flow by inclines 29, 30, into respective streams 3|, 32. Steam blasts from pipes 33 (Fig. 6) extend to discharge jets 34 in heads 35. These V-shaped jets 34 are such as to impinge upon the respective streams 3|, 32, in an efi'icient shredding action as well as projecting the shredded streams in fibrous form.

Importance resides in the location of the stream divider 28. This stream divider 28 is mounted on plate 36 as away from the side of the cupola. The opposite side of this stream divider abuts the plate l for heat conductivity thereto. There is heat conductivity or dissemination from this plate 35 as well as to mounting strip 31 with bolts 35 in slotted arms 35 from frame 45 from the respective cupoias. This distribution of metal as to the portions over which the stream fiows is effective as to the metal extent to resist ready erosion from the molten stream. Furthermore, it may take a sufficiently high temperature while still holding its shape so it is not warped out of shape orotherwise rendered defective. There is sufficient metal with suflicient spacing from the water to permit the metal to carry a high temperature but that such does not go into a critical or detractive region.

Settling chamber From the various heads 35 projected streams 4| (Fig. 1) of fiber from the cupola 5 and 42 from the cupola 4 enter the settling chamber 5 through respective intake openings 43, 44. The settling chamber 5 is shown equipped with endless conveyor slat-forming bottom 45 about idle roller 45 from drive roller 41. This drive roller 41 is driven through transmission 48, speed control means 45, and motor 55 (Fig. 2). From this settling chamber 5 there may be uptake draft portions 5|. It is contemplated the pri- 'mary collection and settling shall be in this chamber 5 as the upper reach 45 of this endless roller 53, and, with the instance herein taken of parallel ribs H of asphalt thereon, the temperature in the settling chamber 5 is suflicient conveyor progresses continuously away from the ports 43, 44, toward the discharge and 1, at which there is opening 52 wherein there is located roller 53 as gravity resting upon the loose bedded fiber 54 tending to reduce the thickness thereof in compacting or working such down into fibrous strata mass 55 as passing under this roller 53.

It is to be noted that in this settling chamber 5 there is transverse shaft 55 having straight vanes 51. This location intermediate the extent of projection from the respective streams 4|, 42, is in position to be impinged. This means there is in the course of transit or travel of these streams a varying length for such travel as the blades or vanes 51 move as to the stream. In practice, these vanes may be actuated by the blast or draft in the chamber. The direction of this rotation seems to be rather delicate in its response according to the particular direction of the respective streams 4|, 42, or possibly the initial position for the vanes as impinged. It is found this direction of rotation may be clockwise or counter-clockwise. A dual purpose seems to develop from this vane structure. There is not a mass accumulation of separate lengths of fiber or as to dimension or accumu-- lation upon one face of the bed. Even as to the presence ofso-called beads" or seeds, experience herein is that these do not in the operation hereunder accumulate superficially or seem to have a presence in clusters. The resulting product as passing under the roller 53 for the compressed bed 55 is of homogeneous felted fiber.

The backing While this uniform body of fiber may pass from the chamber 5 by the opening 52, in the functioning hereunder the roller 53 serves a dual purpose which is beyond that of. compacting from the loose bed 54 into the more close bed 55. This additional functioning has to do with taking from the respective rolls I5 strip paper by way of reach 58 to pass about the to soften or render adherent these asphalt coatings. Accordingly, as from the reach 53 the strip from the roll l5 entering this chamber 5 has this coating rendered sticky or adherent and acting on the bed 54, and such emerges therefrom in adherent relation on a face ll of the upper side of the respective strips on this uniform bed. In practice, these strips may be say of a dimension to go between the studding of a house, say 15 inches for bats to be used in building construction. This means that in the transit from the chamber 5 and as passing under the roll 53 there may be the several continuous strips as determined by the respective rolls I. These parallel strips as along conveyor reach 45 out from the chamber 5 may, in the vicinity of the terminal roll l1, have such bed severed to respond to the strips.

Bed severing longitudinal From drive 53 (Fig. 2) through transmission 50, shaft 5| mounted in bearings 52 at opposite sides of the conveyor, carries a plurality of rotary blades 53 spaced to be effective between the respective strips ll of the paper from the rolls l5. Accordingly, in the transit from this conveyor reach 45 the bed of the fiber is severed by the disks 53. This cutting action is continuous with the feed travel of the bed from the settling chamber.

Chilling At this longitudinal severing region in the take-off at the end of the conveyor bed from the severing chamber, there is chamber 54 to 'which is connected rotary fan 55 (Figs. 1, 3) driven by motor 55. The direction of draft may be elected. However, that which has been found acceptable is a suction draft, and as drawing air from about the bed and through this fiber mass at the cutting there are no fragments scattered about. In this intake draft there is an eifective lowering of the temperature or cooling of this bat having the upper face against the paper strip Accordingly, there is a further drop in the temperature beyond that from leaving the chamber 5 suificient to render this asphalt coating effectively adherent to the felted fiber mass.

Supplemental binding In the event the felting between the fibers be not construed of suflicient anchorage relation therebetween, there may be provision or supply by duct 51 (Fig. 5) to discharge nozzle 58. This means that simultaneously with the delivery streams 4|, 42, of fiber there may be commingled therewith from this jet 58 through the openings 43, 44, a binding agent say rosin or a solvent suflicient that such may be blown thereinto under pressure.

Bat units The continuous strips as passing from the chilling and longitudinal severing of the bed may flow upon table 59 (Fig. 2) having respective conveyor belts 10 thereon driven by transmission 1|. Astride this table may be frame 12. This frame 12 has in a region clearing the table 69 opposing channels 13 forming a pair of parallel tracks on which rollers 14 of truck mount motor 15. This motor 15 has shaft 15 upon which is mounted rocker arm 11 having counterweight 15 at one side from the shaft 15. At the other side from ters Patent, Ser. No. 129,121, filed March a, 1937,

the shaft 16 there is rotary cutting blade I8 driven by belt 80 from the shaft 18. Intermediate the length of this arm between the blade 18 and the shaft 16 and rigid therewith is bracket I having connection 82 with haulage line 83 from idler roller 84 at one end of the frame 12 and drive roller 85 at the other side, actuating the drive motor 88 through transmission 81 as to reversing box 88. This means that in the control with the lower reach of this endless actuator or haulage line 83 in draft toward the roller 88 there is a tilting of this arm on the shaft 18 as an axis to bring the rotary blade 18 clear of the strips of fiber and top face paper covering or backing ll thereon. However, in the reverse direction of travel, that is for this haulage line 88 to have draft toward the roller 84 as to its lower reach, the blade 18 is pulled to swing below the track 13 and thus have this rotary cutter sever the continuous strips of paper from the rolls it into desired length sections, and, as passing further therethrough, approach the belt 10 in going to a major extent through the fibrous body of these bats or units. Byplacing this cutter at a slight angle there may be compensation for its interval of transit. However, the speed of operation, notwithstanding the continuity of the feed, is such that there is in this compressible stock a sufficient accuracy to approach rectangular formation even with the device approximately perpendicular to the line of direction of travel. The extent of venting for the chamber 6 may be controlled by closures 88 (Fig. 2).

The paper sheet Il may be provided with reverse folded strip edges 90 along each side thereof.

Operation In the carrying out of the operation herein, the raw material to the cupolas and the facing material or sheet paper at the rolls I supply the stock. The fiber severing in the fiow off from the cupolas may be accurately adjusted in the blast to be commingled in the settling chamber 6. The bladed member 51 in the settling chamber is a factor in promoting homogeneous characteristics throughout the bed. The heat of the chamber 6 is utilized to soften or melt an asphalt facing on the strip of paper to be top applied to the bat as a backing continuous as emerging and rendered adherent with the compacted fiber as leaving the chamber. promotes this chilling, which, if a blow, may be more rapid in its action than if suction. The bed is severed by the blades 63 to correspond to the strips for the paper l0. While such might be rolled into sections of considerable length, in the building industry convenience is had for handling in having these so-called bats of relatively short rectangular sections, say less than 3 feet or thereabouts in length. Accordingly, such severing is effected in the carrying out of this continuous process by the interposed manual step of this transverse cutting by means of the blade I9 (Fig. 4) This frame instead of being positioned to act toward the belts 10 may be a spacing or groove in the transfer table 69 following the blades 83. In some practice the belts III may feed up strips of paper for the underside of the fibrous matter and such facing may be run from the belts Ill over an incline to clear such stock from the belts or be beyond the belt termini and there severed into the lengths.

This application is a continuation-in-part of my copending application for United States Let- The cooling draft at the chamber 64.

for Rock or mineral wool manufacture.

What is claimed and it is desired to secure by United States Letters Patent is:

1. The method of producing sheet backed fibrous mineral wool sections as a continuous process to form accumulated slag with sufficient silica content, subdivided into fragments to pass through a four inch mesh screen to form a charge, wherein delivery is had of such charge for melting at a suitable temperature therefor, drawn oil. from the melting in stream continuity, simultaneous blasting transversely a plurality of the streams into fiber by projecting the fiber.

therefrom, commingling of the fiber being promoted abruptly changing the course of fiber projection, the fiber having been settled to form a continuously moving bed, comprising the steps of utilizing residual melting heat from the projected fiber thereby to soften a coated faced sheet, supplying said sheet softened coating side directly against the moving sheet in simultaneous common direction of travel therefor, holding the sheet against the bed, chilling the bed and sheet for establishing of adherence between the bed and sheet, and subdividing the bed and sheet into sheet backed sections.

2. The method of producing mineral wool fiber sections comprising directing a blast through a stream of hot molten material, settling said material into a bed, supplying sheet material free from adherent facing at normal temperature, utilizing heat from the material in transit to the bed to render a sheet adherent, placing said sheet on the bed, and chilling said sheet into adherence with the bed.

3. A mineral fiber manufacturing installation embodying a settling chamber having the conveyor forming a carrying bed for the fiber, a roller opposing the bed and compacting the fiber thereagainst at a discharge from the chamber,

'supply means for sheet stock having facing normally severable from abutting relation, and directing means to pass said sheet stock about the roller and thence upon the upper side of the bed as from said chamber, said sheet stock being rendered adherent by heat in the chamber for assembly of said sheet stock with the bed as passing the roller from the chamber.

4. A mineral fiber manufacturing installation embodying a settling chamber having the conveyor forming a carrying bed for the fiber, a roller opposing the bed, and compacting the fiber thereagainst at a discharge from the chamber, directing means for placing normally self-freeing sheet stock from a supply to pass about the roller and thence upon the upper side of the bed as from said chamber, said sheet stock being changed over from its non-adherent condition by heat in the chamber for assembly of said sheet stock with the bed as passing the roller from the chamber, and means for establishing a cooling to promote adherence between the sheet and bed.

5. The method of producing sheet backed fibrous mineral wool sections as a continuous process from accumulated slag with sufiicient silica content, subdivided into fragments to pass through a four inch mesh screen in forming a charge, there having been delivery of such charge for melting at a suitable temperature therefor, drawn off from the melting through dififerent levels subdivided into streams, said streams being simultaneously blasted into fiber, transversely of the different levels, by projecting the fiber therefrom, commingling of the fiber having been promoted by intercepting the projected fiber by impinging action from the blasts in thereby abruptly changing the course of fiber projection, the steps comprising settling the fiber to form a continuously moving bed, supplying a sheet 01' facing coated for severability at normal temperature, utilizing heat from the projected fiber to soften said coating of the sheet, supplying said sheet softened coating side directly against the moving sheet in simultaneous common direction of travel therefor, holding the sheet against the bed, chilling the bed and sheet for establishing of adherence between the bed and sheet, and subdividing the bed and sheet into sheet backed sections.

CLINTON L. SAVIDGE.

csnnmcuz or" conmacmbm Patent No. 2,295,971 September 15;"19k2.

cmmron L. snnm.

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